ENGINE UNIT REMOVAL

PROCEDURE


  1. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A00021E

      Remove the engine oil level dipstick.

    2. Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  2. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A0001W2

      Remove the bolt and V-ribbed belt tensioner assembly.

  3. REMOVE COMPRESSOR ASSEMBLY WITH MOTOR

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  4. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A0001YB

      Remove the 4 bolts and No. 1 compressor mounting bracket.

  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  6. REMOVE NO. 2 EGR PIPE (w/ EGR System)

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  7. REMOVE NO. 2 MANIFOLD STAY

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  8. REMOVE MANIFOLD STAY

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  9. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  10. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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  11. REMOVE WATER BY-PASS PIPE (w/ EGR System)


    1. A0000NH

      Remove the 4 bolts, water by-pass pipe and 2 gaskets.

  12. REMOVE EGR COOLER ASSEMBLY (w/ EGR System)


    1. A0001VM

      Slide the hose clamp and disconnect the No. 5 water by-pass hose from the EGR cooler assembly.

    2. A0001IJ

      Remove the bolt and nut, and disconnect the No. 1 EGR pipe from the EGR cooler assembly.

    3. A0000D9

      Remove the bolt, nut and EGR cooler assembly.

    4. Remove the gasket from the No. 1 EGR pipe.

  13. REMOVE NO. 5 WATER BY-PASS HOSE (w/o EGR System)


    1. A0001CH

      Slide the 2 hose clamps and remove the No. 5 water by-pass hose from the water by-pass pipe and No. 3 water by-pass pipe.

  14. REMOVE NO. 1 WATER BY-PASS PIPE (w/o EGR System)


    1. A000154

      Remove the 3 bolts, No. 1 water by-pass pipe and gasket.

  15. REMOVE EGR VALVE ASSEMBLY (w/ EGR System)

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  16. REMOVE NO. 3 WATER BY-PASS HOSE


    1. A0000FS

      Slide the hose clamp and remove the No. 3 water by-pass hose.

  17. REMOVE NO. 1 WATER BY-PASS HOSE (w/ EGR System)


    1. A0000M3

      Slide the hose clamp and remove the No. 1 water by-pass hose from the cylinder block.

  18. REMOVE NO. 1 EGR PIPE (w/ EGR System)


    1. A0001PD

      Remove the 2 bolts and No. 1 EGR pipe.

  19. REMOVE NO. 3 WATER BY-PASS PIPE (w/o EGR System)


    1. A00025L

      Remove the 2 bolts and No. 3 water by-pass pipe.

  20. REMOVE ENGINE WATER PUMP ASSEMBLY

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  21. REMOVE WATER INLET

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  22. REMOVE THERMOSTAT

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  23. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)

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  24. REMOVE WATER INLET HOUSING


    1. A0001D2

      Remove the 3 bolts, nut and water inlet housing from the cylinder block.

    2. A0001ZP

      Remove the gasket.

    3. A0001ZY

      Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the water inlet housing.

      Note

      If a stud bolt is deformed or its thread is damaged, replace it.

  25. REMOVE INTAKE MANIFOLD


    1. B002KUB

      Slide the clamp and disconnect the No. 2 PCV hose from the intake manifold.

    2. B002KIQ

      Slide the clamp and disconnect the purge line hose from the intake manifold.

    3. B002IMC

      Remove the 6 bolts and intake manifold.

    4. B002KUS

      Remove the No. 1 intake manifold to head gasket from the intake manifold.

  26. REMOVE FUEL DELIVERY PIPE

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  27. REMOVE INJECTOR VIBRATION INSULATOR

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  28. REMOVE SENSOR WIRE


    1. A0000OH

      Disconnect the knock control sensor connector.

    2. Remove the bolt and sensor wire.

  29. REMOVE IGNITION COIL ASSEMBLY

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